CN115697120A

CN115697120A - Post production laser modification of articles of footwear

Info

Publication number: CN115697120A
Application number: CN202180036920.7A
Authority: CN
Inventors: 德尔文·A·詹姆斯; 埃里克·S·斯金勒
Original assignee: Nike Innovate CV USA
Current assignee: Nike Innovate CV USA
Priority date: 2020-05-31
Filing date: 2021-05-27
Publication date: 2023-02-03
Also published as: WO2021247375A3; US20210368924A1; WO2021247375A2; KR20230016678A; US11633012B2; EP4157009A2

Abstract

A sole assembly for an article of footwear includes a midsole formed from at least a bladder and a foam midsole component. The midsole has a ground-facing surface and a sidewall, and the bladder interfaces with the foam midsole at a component boundary on the sidewall. The etchings extend into both the foam midsole and the bladder. The etched channels have a depth in the sidewalls of between about 2mm and about 1000 μm and extend continuously across the feature boundaries.

Description

Post production laser modification of articles of footwear

Cross Reference to Related Applications

This application claims priority from U.S. provisional patent application No. 63/032,688, filed on 31/5/2020, which is incorporated by reference in its entirety.

Technical Field

The present teachings relate generally to ways of using laser etching devices to decoratively modify an article of footwear.

Background

Footwear typically includes a sole that is configured to be positioned under a foot of a wearer to space the foot from a ground or floor surface. The sole may be designed to provide a desired level of cushioning. The sole may be an assembly that includes a midsole and an outsole. Particularly athletic footwear, sometimes use polyurethane or ethylene vinyl acetate foam or other resilient materials in the sole to provide cushioning. In some configurations, the sole may also include one or more fluid-filled chambers (chambers) to vary cushioning properties.

SUMMARY

In one configuration, a sole assembly for an article of footwear includes a midsole formed from at least a bladder (blader) and a foam midsole component. The midsole has a ground-facing surface and a sidewall, and the bladder interfaces with the foam midsole at a component boundary on the sidewall. An etched portion (etching) extends into both the foam midsole and the bladder. The etched channels have a depth in the sidewalls of between about 2 μm and about 1000 μm and extend continuously across the feature boundaries.

Further, in some embodiments, an article of footwear includes an upper defining an interior cavity operable to receive a foot of a wearer and a sole structure coupled to the upper. The sole structure includes a ground-contacting surface opposite the upper, a midsole formed from a thermoplastic polymer foam, and a fluid-filled bladder. The midsole has a foam sidewall that defines a first portion of an outer perimeter of the sole structure. The foam sidewall extends upwardly at an angle relative to the ground-contacting surface, and the fluid-filled bladder has a bladder sidewall defining a second portion of the outer perimeter of the sole structure. The cell sidewall directly abuts the foam sidewall at the component boundary. Finally, the etchings extend continuously from the foam sidewall across the component boundary to the bladder sidewall.

In further aspects of the disclosure, the etchings may form a graphical design or logo, and may be created from a visual image received via a network computing system. In some embodiments, the etched portion may at least partially expose or also make visible the inner material layer, which may be colored differently than the outermost material layer. The etchings may include texture that may be useful for individuals with visual defects in distinguishing between a left shoe and a right shoe in a coordinated pair of shoes. In addition, the etchings may provide a unique identifier from which the authenticity of the article of footwear may be determined. Additional aspects and advantages of the present design are provided below, including related methods for creating an etch.

Brief Description of Drawings

FIG. 1 is a side perspective view of an article of footwear according to the principles of the present disclosure;

FIG. 2 is an exploded view of the article of footwear of FIG. 1, showing the article of footwear having an upper and a sole structure arranged in a layered configuration;

FIG. 3 is a schematic diagram of a laser etching system;

FIG. 4 is a schematic view of a design applied to a sidewall of an article of footwear;

FIG. 5 is a schematic flow chart of a method of laser etching an article of footwear.

Detailed Description

The present disclosure generally relates to a manner of altering the visual and/or tactile properties of an article of footwear after the article of footwear is fully assembled. In doing so, the graphics or tactile texture may extend continuously across multiple adjacent components, which may otherwise be difficult to perform properly if the graphics or texture is applied prior to assembly.

Example configurations will now be described more fully with reference to the accompanying drawings. These configurations are provided so that this disclosure will be thorough and will fully convey the scope of the disclosure to those skilled in the art. Specific details are set forth such as examples of specific components, devices, and methods in order to provide a thorough understanding of the configurations of the present disclosure. It will be apparent to one of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that specific details and example configurations should not be construed as limiting the scope of the disclosure.

The terminology used herein is for the purpose of describing particular example configurations only and is not intended to be limiting. As used herein, the singular articles "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having" are inclusive and therefore specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.

When an element or layer is referred to as being "on," "engaged to," "connected to," "attached to" or "coupled to" another element or layer, it may be directly on, engaged, connected, attached or coupled to the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," "directly attached to" or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between," "directly adjacent to," etc.). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers, and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.

Referring to fig. 1-2, article of footwear 10 includes an upper 100 and a sole structure 200. Article of footwear 10 may be divided into one or more regions. These areas may include forefoot region 12, midfoot region 14, and heel region 16. Midfoot region 14 may correspond with the arch area of the foot, and heel region 16 may correspond with rear portions of the foot, including the calcaneus bone. Footwear 10 may also include a forward end 18 associated with a forward-most point of forefoot region 12, and a rearward end 20 corresponding with a rearward-most point of heel region 16. A longitudinal axis of footwear 10 extends generally along a length of footwear 10 from a forward end 18 to a rearward end 20, and generally divides footwear 10 into a lateral side and a medial side. Accordingly, lateral and medial sides correspond with opposite sides of footwear 10, respectively, and extend through

regions

12, 14, 16.

Upper 100 includes an interior surface that defines an interior void 102, interior void 102 being configured to receive and secure a foot for support on sole structure 200. Upper 100 may be formed from one or more materials that are stitched or adhesively bonded together to form interior void 102. Suitable materials for the upper may include, but are not limited to, mesh, textile (textile), foam, leather, and synthetic leather. These materials may be selected and positioned to impart properties of durability, breathability, abrasion resistance, flexibility, and comfort.

Referring to fig. 2, in some examples, upper 100 includes strobel 104, strobel 104 having a bottom surface opposite sole structure 200 and an opposite top surface defining a footbed (foot bed) of interior cavity 102. Stitching or an adhesive may secure the strobel to upper 100. The footbed may be contoured to conform to the contours of the bottom surface of the foot (e.g., the plantar (plantar)). Optionally, upper 100 may also incorporate an additional layer (such as an insole or sockliner) that may be disposed on strobel 104 and placed within interior void 102 of upper 100 to receive the plantar surface of the foot to enhance the comfort of article of footwear 10. An ankle opening 114 in heel region 16 may provide access to interior cavity 102. For example, ankle opening 114 may receive the foot to secure the foot within void 102 and facilitate entry and removal of the foot from interior void 102.

In some examples, one or more fasteners 110 extend along upper 100 to adjust the fit of upper 100 around the foot and to accommodate entry and removal of the foot into and out of upper 100. Upper 100 may include apertures 112, such as eyelets, and/or other engagement features that receive fasteners 110, such as fabric or mesh loops. The fasteners 110 may include laces, straps, cords, staples, or any other suitable type of fastener. Upper 100 may include a tongue portion 116 that extends between interior void 102 and the fastener.

With continued reference to fig. 1-2, sole structure 200 includes a cushioning component 208, with cushioning component 208 defining a portion of an outer periphery of sole structure 200 in heel region 16. Cushioning component 208 may include a fluid-filled bladder 210 and an outsole portion 220. In some configurations, outsole portion 220 may be integrally coupled with fluid-filled bladder 210, such as via an over-molding process (over-molding process), or also by integrally molding outsole portion 220 when forming the walls of bladder 210. Outsole portion 220 extends along the ground-facing side of fluid-filled bladder 210 and may define a first portion of ground-engaging surface 202 of sole structure 200.

Sole structure 200 also includes a forward midsole component 230 in forefoot region 12 and midfoot region 14. The front midsole component 230 may be formed from an energy-absorbing material, such as, for example, a polymer foam. Forming the front midsole component 230 from an energy-absorbing material (such as a polymer foam) allows the front midsole component 230 to attenuate ground reaction forces that are caused by movement of the article of footwear 10 over a ground surface during use.

Referring to fig. 2, the fluid-filled bladder 210 may be formed from a plurality of polymeric sheets (e.g., a first polymeric sheet 212a and a second polymeric sheet 212 b) that are fused together at a peripheral flange or seam 214 to define an interior volume between the

respective sheets

212a, 212b. The interior volume is adapted to receive a pressurized fluid (e.g., air) that may provide a cushioning mass to the sole structure. In some embodiments, seam 214 may extend around some or all of the perimeter of fluid-filled bladder 210, but may preferably be hidden by outsole portion 220. Although seam 214 is shown as forming a relatively distinct flange projecting outwardly from fluid-filled bladder 210, in some embodiments seam 214 may be a flat seam such that upper polymeric sheet 212a and lower polymeric sheet 212b are substantially continuous with one another. In some embodiments, additional polymeric sheets may be provided between the first and

second polymeric sheets

212a, 212b to define one or more additional volumes within the fluid-filled bladder 210.

The first and

second polymeric sheets

212a and 212b may each be formed from one or more layers of a substantially transparent thermoplastic material, such as a Thermoplastic Polyurethane (TPU). Examples of other suitable polymeric materials that may be used to form fluid-filled bladder 210 include thermoplastic polyurethanes, polyesters, polyester polyurethanes, and polyether polyurethanes. Further, each of the

polymer sheets

212a, 212b forming the fluid-filled bladder 210 may include layers of different materials. In one embodiment, the

polymer sheets

212a, 212b may be formed from a plurality of alternating films comprising one or more layers of Thermoplastic Polyurethane (TPU) and one or more barrier layers comprising a copolymer of ethylene and vinyl alcohol (EVOH). In use, the EVOH layers may be configured such that they are impermeable to the pressurized fluid contained therein. Such a configuration is further disclosed in U.S. patent No. 6,082,025 to Bonk et al, which is incorporated by reference in its entirety.

In some embodiments, the

polymer sheets

212a, 212b may also be formed from a material that includes alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in U.S. patent nos. 5,713,141 and 5,952,065 to Mitchell et al, both of which are incorporated by reference in their entirety. Alternatively, the layers may include ethylene vinyl alcohol copolymer, thermoplastic polyurethane, and regrind material of ethylene vinyl alcohol copolymer and thermoplastic polyurethane. The

polymeric sheets

212a, 212b of fluid-filled bladder 210 may also be flexible microlayer films that include alternating layers of a gas barrier material and an elastomeric material, as disclosed in U.S. Pat. Nos. 6,082,025 and 6,127,026 to Bonk et al, both of which are incorporated by reference in their entirety. Additional suitable materials for fluid-filled bladder 210 are disclosed in U.S. patent nos. 4,183,156 and 4,219,945 to Rudy, both of which are incorporated by reference in their entirety. Additional suitable materials for fluid-filled bladder 210 include thermoplastic films containing crystalline materials (as disclosed in U.S. patent nos. 4,936,029 and 5,042,176 to Rudy), and polyurethanes including polyester polyols (as disclosed in U.S. patent nos. 6,013,340, 6,203,868, and 6,321,465 to Bonk et al), which are incorporated by reference in their entirety.

Engineering properties such as tensile strength, tensile properties, fatigue properties, dynamic modulus, and loss tangent may be considered in selecting a material for fluid-filled bladder 210. The thickness of the

polymer sheets

212a, 212b used to form the fluid-filled bladder 210 may be selected to provide these characteristics. The fluid-filled bladder 210 is resilient and provides cushioning and flexibility that can be adjusted, such as by selecting a pressurization level. Optionally, tensile members and/or reinforcing structures may be integrated with fluid-filled bladder 210 to provide the desired responsiveness, such as disclosed in U.S. Pat. No. 4,906,502 to Rudy et al and U.S. Pat. No. 8,061,060 to Swigart et al, which are incorporated by reference in their entirety.

In some embodiments, outsole portion 220 extends over a portion of bladder 210 to provide bladder 210 with increased durability and resiliency. Accordingly, outsole portion 220 may be formed from a different material than bladder 210 and include at least one of a different thickness, a different hardness, and a different wear resistance than second/lower polymer sheet 212b. In some examples, outsole portion 220 may be integrally formed with second polymer sheet 212b of bladder 210 using an overmolding process. In other examples, the outsole portion 220 may be formed separately from the second polymeric sheet 212b and may be adhesively bonded to the second barrier layer 212b by a subsequent process.

With continued reference to fig. 1-2, the fluid-filled bladder may be continuously exposed along the outer perimeter of heel region 16 from a distal end 219 on the lateral side to a similar distal end on the medial side. For example, the first barrier layer 212a may be continuously exposed along an outer periphery of the sole structure 200 between the upper 100 and the outsole portion 220 such that the transparent first polymeric sheet 212a is exposed around a periphery of the heel region 16.

The sole structure 200 may also include a heel counter 270, and the heel counter 270 may be formed from the same transparent TPU material as the first polymer sheet 212a and may extend further onto a portion of the forward midsole component 230. As shown, heel counter 270 extends from first distal end 219 of bladder 210 around rear end 20 and to the distal end of bladder 210 located on the opposite side of sole structure 200.

In general, fluid-filled bladder 210 and front midsole component 230 may cooperate to define at least a portion of an overall midsole for the article of footwear. The midsole typically has an outwardly facing midsole sidewall formed at least in part by a fluid-filled bladder sidewall and a forward midsole component sidewall. The midsole sidewall may extend generally upward from the ground-engaging surface 202 toward the upper, and may form at least a portion of the overall side profile of the article of footwear 10.

In one embodiment, article of footwear 10, and in particular sole structure 200 of the article of footwear, may be customized in its visual and/or tactile appearance by using an etching process. In particular, a laser etching system 300 such as that shown in fig. 3 may be used to scribe one or more designs into the midsole sidewall, where the designs may extend across one or both of the fluid-filled bladder sidewall and the forward midsole component sidewall. The system 300 may generally include a laser head 302, a workpiece holder 304 configured to hold and/or move a workpiece 306, a movement system 308 configured to provide motion between the laser head 302 and the workpiece, and a computer numerical controller 310 configured to control movement between the laser head 302 and the workpiece. Laser head 302 may emit an intense beam of light at a particular wavelength and may be driven by a laser oscillator 312, which laser oscillator 312 is in turn powered by a transformer 314.

Laser etching system 300 may include any suitable type of laser cutter for cutting sole material. For example, laser etching system 300 may include a pulsed fiber laser, a continuous wave carbon dioxide laser, an ultraviolet solid state laser, a yttrium lithium fluoride laser, or an excimer (compound excited) laser cutter, such as a 5-axis computer numerically controlled laser cutter ML1515VZ20 manufactured by Mitsubishi Corporation. In another example, sumitomo Heavy Industries, ltd. Manufactures a laser cutter, such as a KrF excimer laser INDEX-848K with a wavelength of 248 nm.

The wavelength of the laser may vary depending on the nature of the material to be cut and the desired effect. In some embodiments, the wavelength may be in the ultraviolet portion of the spectrum, i.e., from about 10nm to about 400nm. In other embodiments, a particular portion of the ultraviolet spectrum may be selected, such as from about 200nm to about 300nm. For example, for many polymers, 248nm light may be effective for cutting/etching. In other embodiments, other portions of the electromagnetic spectrum may be selected for the laser. Infrared light may also be selected, for example, carbon dioxide lasers in the wavelength range of 940nm-1064nm may be desirable for certain materials/effects. In other embodiments, lasers operating at 355nm, 532nm, and 1064nm may be desirable. When used with thermoplastics, IR (e.g., >700 nm) lasers may tend to thermally transform/melt the polymer (i.e., "hot" processes), while UV lasers (e.g., <400 nm) may break molecular bonds at the skin layer in "cold" photoablation processes, which may produce smoother edge features. Similar to the selection of the wavelength, the power of the laser and/or the duration of any laser pulse or exposure to the laser beam may be selected according to factors such as the wavelength, power source, type of material desired to be cut/etched, and type of cutting/etching effect desired.

The laser head 302 may be connected to a laser oscillator 312 and may be configured to focus laser light generated by the laser oscillator 312. The laser head 302 may include a laser nozzle 316 disposed on the bottom of the laser head 302. The laser nozzle 316 may be configured to further focus the laser and emit a laser beam, and may be adjusted to increase and/or decrease the focus of the laser beam. In some embodiments, the laser nozzle 316 may be adjusted by a local processing device 318. The local processing device 318 is discussed in more detail below. The type of laser head 302 and/or laser nozzle 316 may be selected based on a variety of factors. For example, the type of laser head and laser nozzle may be selected based on the type of laser cutter used and/or the desired depth and shape of the etched pattern.

The workpiece retainer 304 may include any suitable type of retainer operable to retain an article of footwear. For example, as shown in FIG. 3, the workpiece holder 304 may include a workpiece stage 320. In other embodiments, the workpiece holder 304 may include a last on which the article of footwear is mounted.

The laser etching system 300 of fig. 3 may include a movement system 308 that provides motion between the laser head 302 and the workpiece, for example, ML1515VZ20 from mitsubishi corporation, as described above. In one configuration, laser etching system 300 may include a 5-axis cutter configured to move laser head 302 in three directions and move the workpiece in two directions. In some embodiments, laser etching system 300 may include a 5-axis cutter configured to move laser head 302 in two directions and move the workpiece in three directions. Alternatively, the laser etching system 300 may include a 6-axis cutter configured to move the laser head 302 in three directions and to move the workpiece in three directions. Providing multiple directions of movement between the laser head 302 and the workpiece holder 304 may provide the possibility of many etching patterns.

When used to etch a visual pattern in sole structure 200, the laser beam emitted from laser head 302 may be adjusted to keep the surface of sole structure 200 smooth after cutting, yet may change the visual appearance of the polymer. In some embodiments, the laser beam emitted from laser head 302 may be adjusted to leave a mark in the wake of the laser beam. The markings produced by laser cutting may be so fine and uniform that the roughness of the resulting surface of sole structure 200 may be very low or unchanged relative to the pre-etched state. In some embodiments, laser etching system 300 of fig. 3 may be used to cut fine lines and/or other repeating patterns, which may add texture to the surface of sole structure 200.

As described above, the laser etching system 300 may include a computer numerical controller 310, the computer numerical controller 310 configured to control movement between the laser head 302 and the workpiece. For example, as described above, mitsubishi manufactures a 5-axis computer numerically controlled laser cutter, such as ML1515VZ20. In some embodiments, the computer numerical controller 310 may be configured to control the focus of the laser beam emitted from the laser head 302. The computer numerical controller 310 may include any suitable type of computer numerical controller. The type of computer numerical controller may be selected based on various factors. For example, the type of computer numerical controller may be selected based on the type of laser head and/or the type of workpiece stage used.

The laser etching system 300 of fig. 3 may include local processing equipment 318 operable to control the laser head 302 and/or the computer numerical controller 310. In some embodiments, the local processing device includes a local user interface operable to configure the system 300. The local processing device 318 may include one or more special purpose processors, or one or more computing devices in local communication with the computer numerical controller 310. For example, in some embodiments, local processing device 318 may comprise a desktop or laptop computer, a tablet computer, or a suitable portable computing device in wired or direct wireless communication with computer numerical controller 310.

In some embodiments, the local processing device 318 may communicate with one or more networked user interfaces 322 over a digital computer network, a local area network, a wide area network, or over point-to-point RF communications, such as using the bluetooth protocol. Networked user interface 322 may be displayed or provided on any suitable portable computing device, such as a smartphone, tablet, laptop, or similar device, and may enable a user to provide one or more designs 324 that are desired to be etched into sole structure 200. In some embodiments, the networked user interface 322 may comprise a dedicated application operating on the user's device, or may comprise an internet-based web application viewable through a suitable internet browser.

As shown in fig. 3, a user may access the networked user interface 322 via a display screen or other human interface device in response to a set of user prompts. For example, the display screen may be a touch screen, and the user prompt may be one or more icons and/or text-based prompts requesting input of a desired surface feature or design (such as a customized depth, pattern, or effect that may be etched into sole structure 200). Alternatively, the user prompt may request that a desired logo be entered on the exterior surface of sole structure 200, where the term "logo" as used herein refers to any image, letter, character, or the like that will effectively form a customized watermark or etched image.

As described above, in one embodiment, article of footwear 10, and in particular sole structure 200 of the article of footwear, may have a visual appearance that it is customized via laser etching system 300. In particular, laser etching system 300 may be configured to controllably apply laser energy to an exterior surface of article of footwear 10 for the purpose of altering the visual properties of the material used to form the article and/or altering the physical properties of the article itself.

Fig. 4 schematically illustrates one embodiment of an article of footwear 10 having an etched pattern 350 imprinted into an outer surface 352. As generally shown, the etched pattern 350 may extend continuously across multiple features without interruption. In a particular embodiment, such continuous aspects of the etched pattern 350 can be formed by controlling the movement system 308, the computer numerical controller 310, and/or the workpiece holder 304 such that the laser beam emitted from the laser head 302 is approximately orthogonal to the outer surface 352 at the point where the laser beam impinges on the outer surface.

Fig. 5 schematically illustrates an embodiment of a method 400 for laser etching an article of footwear. As shown, the method 400 may include providing (or receiving) an article of footwear 10 on a workpiece holder 304 (at 402), and identifying a contour or outer surface contour of the article of footwear (at 404), followed by identifying an etchable working space on the outer surface of the article (at 406). Identifying the outline profile may occur manually (such as by receiving an indication of the model and size of the article of footwear from a user interface), or automatically (such as by scanning an outer surface of the article with a laser, for example). In one embodiment, the identified etchable workspace extends continuously over multiple components, such as a polymer foam midsole (e.g., the forward midsole component 230 shown in fig. 1-2), a polymer fluid-filled chamber (e.g., the fluid-filled chamber 210 shown in fig. 1-2), and/or a heel counter (e.g., the heel counter 270 shown in fig. 1-2).

The method 400 also includes receiving (at 408) the design from the user via the local processing device 318 and/or the networked user interface 322. In one configuration, the design may include a repeating pattern of discrete graphics primitives, such as a repeating grid pattern or a repeating chevron design. In another configuration, the design may include more complex graphics, such as logos, pictures, or other creative works.

After receiving the design at 408, the local processing device 318 may apply/project the design onto the etchable workspace (at 410), and then build a series of digital codes (at 412) that can be used to instruct the movement system 308 and/or the computer numerical controller 310 to move the laser head 302 so that the laser beam tracks the design onto the article (at 414). In one embodiment, the local processing device 318 may utilize the dimensional geometry of the outer surface of the article to construct a digital code that maintains the laser beam in an approximately orthogonal orientation to the surface it illuminates. After the digital code is created, the local processing equipment may instruct the movement system 308 and/or computer numerical controller 310 to move the laser head 302 while modulating the power of the laser oscillator 312 and/or the laser to etch a specified design into the article.

Applying the design in this manner may result in a complete article having at least one etch line formed by the laser that extends continuously across the boundary between the two components. In one embodiment, the laser may cut or locally melt the outer surface of one or more components to create channels having a depth of between about 2 μm and about 1000 μm, or between about 2 μm and about 500 μm, or between about 2 μm and about 125 μm, or even between about 2 μm and about 25 μm, as measured from one or more directly adjacent step regions.

In one embodiment, at least one of the midsole (e.g., the front midsole component 230 shown in fig. 1-2), the polymer fluid-filled chamber (e.g., the fluid-filled chamber 210 shown in fig. 1-2), and/or the heel counter (e.g., the heel counter 270 shown in fig. 1-2) may have an outer skin or outer material construction that includes multiple layers. One or more layers may have a substantially constant thickness, and at least two layers may be formed of materials having different pigmentation. In such embodiments, the depth of the laser etching may be greater than 75% of the thickness of the outermost layer, such that the second layer (i.e., the layer immediately below the outermost layer) may be at least partially visible through the remaining material of the etching channels and/or the outer layer. In one embodiment, the depth of the laser etching may be greater than or equal to the thickness of the outermost layer such that the second layer is at least partially exposed within the channel formed via the etching. In some configurations, the second layer may be a different color than the outermost layer, and may also be visible only through the etched channels.

In another embodiment, the etching process may change one or more pigments at an outer surface of the sole structure 200, or may change the light transmittance of a polymer, such as in the barrier layer 212a of the fluid-filled chamber 210. The alteration of the pigmentation and/or transmittance of the polymer may occur, for example, by altering the polymer chain structure or by initiating a hyper-localized chemical reaction that results in a visible change.

The etchable workspace may include various portions of the article of footwear, including a toe bumper (toe bumper), sidewalls of the sole structure, a ground-facing surface, a heel counter, a fluid-filled chamber, and/or an upper.

In some configurations, the methods and systems described herein may be used to apply a texture to an exterior surface of an article of footwear and across a plurality of discrete components. Such texturing may enable non-visual differentiation between right and left shoes, which may be beneficial for individuals with visual impairments. For example, in one configuration, the texture may be applied to only one shoe in a respective pair of shoes. In another configuration, a similar texture may be applied to each shoe, however, the texture may be applied to only one of the lateral or medial sides of each article (however in agreement between the two-i.e., both lateral or both medial sides). In yet another configuration, a first texture may be applied to a first article in a respective pair of shoes, while a second texture distinguishable from the first texture may be applied to a second article in a pair. In these embodiments, the applied texture may generally comprise a recessed or etched surface profile having sufficient roughness or surface geometry to be perceptible and recognizable by human touch.

In yet another configuration, the applied pattern or indicia may contain sufficient unique content to authenticate the article of footwear as genuine rather than counterfeit. In particular, the ability to create a convincing replica may be further complicated by etching across multiple components of the sole and/or upper. In one configuration, the authentication or identification indicia may be digitally encoded within a wider texture or visual design, such as described in U.S. patent application No. 17/116,527, which is incorporated by reference in its entirety and discloses the entire contents thereof.

While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative only and not limiting.

Claims

1. A sole assembly for an article of footwear, comprising:

a midsole comprising a bladder and a foam midsole component, wherein the bladder defines a fluid-filled chamber, the foam midsole component having a ground-facing surface and a sidewall, and wherein the bladder forms a visible portion of the sidewall, and wherein the bladder interfaces with the foam midsole component to define a component boundary on the sidewall;

an etched channel extending into both the foam midsole component and the bladder, the etched channel having a depth in the sidewall between about 2 μm and about 1000 μm, and wherein the etched channel extends continuously across the component boundary.

2. The sole structure of claim 1, wherein the etched channels form a design or logo.

3. The sole structure of claim 1, wherein at least one of the bladder or the foam midsole component includes a plurality of material layers, wherein an outermost layer forms an outer surface of the midsole; and is

Wherein the depth is greater than 75% of the thickness of the outermost layer.

4. The sole structure of claim 3, wherein the plurality of material layers includes a second layer directly adjacent to the outermost layer; and is provided with

Wherein the second layer is at least partially visible through the etch channel.

5. The sole structure of claim 4, wherein the second layer is a different color than the outermost layer, and wherein the second layer is visible only through the etched channels.

6. The sole structure of claim 1, wherein the bladder has a convex surface profile relative to the sole structure, and wherein the etched channels are formed at least partially into the convex surface profile.

7. An article of footwear having a forefoot portion, a midfoot portion, and a heel portion, the article of footwear comprising:

an upper defining an interior cavity operable to receive a foot of a wearer;

a sole structure coupled to the upper, the sole structure including:

a ground contacting surface opposite the upper;

a midsole formed from a thermoplastic polymer foam;

a fluid-filled bladder; and is provided with

Wherein the midsole has a foam sidewall defining a first portion of an outer perimeter of the sole structure, the foam sidewall extending upwardly at an angle relative to the ground-contacting surface;

wherein the fluid-filled bladder has a bladder sidewall defining a second portion of the outer perimeter of the sole structure, the bladder sidewall directly abutting the foam sidewall at a component boundary; and

an etched portion extending continuously from the foam sidewall across the component boundary to the bladder sidewall.

8. The article of footwear of claim 7, wherein the etched portion includes a channel having a channel depth of between about 2 μ ι η and about 1000 μ ι η relative to an adjoining outer perimeter.

9. The article of footwear recited in claim 7, wherein the fluid-filled bladder is disposed in the heel portion of the article of footwear.

10. The article of footwear recited in claim 9, wherein the bladder sidewall is convex in a plane orthogonal to the ground-contacting surface.

11. The article of footwear of claim 7, wherein the etched portion forms a design or logo.

12. The article of footwear of claim 7, wherein at least one of the fluid-filled bladder or the foam midsole includes a plurality of material layers, wherein an outermost layer forms an exterior surface of the sole structure; and is

Wherein the etched portion has a depth greater than 75% of a thickness of the outermost layer.

13. The article of footwear recited in claim 12, wherein the plurality of material layers includes a second layer directly adjacent to the outermost layer; and is

Wherein the second layer is at least partially visible by the etching.

14. The sole structure of claim 13, wherein the second layer is a different color than the outermost layer, and wherein the second layer is visible only through the etched portion.

15. An article of footwear having a forefoot portion, a midfoot portion, and a heel portion, the article of footwear comprising:

an upper defining an interior cavity operable to receive a foot of a wearer;

a sole structure coupled to the upper, the sole structure including:

a ground contacting surface opposite the upper;

a midsole formed from a thermoplastic polymer foam, the midsole having a foam sidewall that defines at least a portion of an outer perimeter of the sole structure, the foam sidewall extending upwardly at an angle relative to the ground-contacting surface;

a heel counter having a heel counter sidewall that defines a portion of the outer perimeter of the article of footwear, the heel counter sidewall directly abutting the foam sidewall; and

an etched portion extending continuously from the foam sidewall to the heel counter sidewall.

16. The article of footwear according to claim 15, wherein the etched portion includes a channel having a channel depth of between about 2 μ ι η and about 1000 μ ι η relative to an adjoining outer perimeter.

17. The article of footwear according to claim 15, wherein the sole structure further includes:

a fluid-filled bladder having a bladder sidewall defining a portion of the outer perimeter of the sole structure, the bladder sidewall directly abutting the foam sidewall; and is

Wherein the etchings extend continuously from the foam sidewall to the bladder sidewall and continuously from the heel counter to the bladder element.